Apparatus for coating a substrate quickly and uniformly with a small volume of fluid

ABSTRACT

A method is provided for applying a fluid onto a surface of a solid substrate. The method employs a distribution member having an upper surface and a lower surface, and including a permeable portion having channels therethough. The distribution member is positioned such that the lower surface of the distribution member is in opposing relation to the surface of the substrate. Once the distribution member is in position, the fluid is dispensed onto the upper surface of the permeable portion of the distribution member such that the fluid penetrates the distribution member and is retained thereby. In addition, a distribution pressure differential is applied between the upper and lower surfaces without using mechanical means such as a squeegee so that a portion of the fluid passes through the channels of the permeable portion of the distribution member and onto the solid substrate surface. Other embodiments of the invention include an apparatus for carrying out the aforementioned method and a reagent application station for applying a plurality of reagents onto a surface of a solid substrate.

This is a Divisional of application Ser. No. 09/494,187, filed on Jan.28, 2002 now U.S. Pat. No. 6,406,851 B1, the entire disclosure of whichis incorporated herein by reference.

TECHNICAL FIELD

This invention relates generally to a method and apparatus to coat asubstrate with a small volume of fluid. More particularly, the inventionrelates to a method and apparatus to quickly and uniformly coat a fluidsuch as reagents or fluids used in DNA array fabrication onto a surfaceof a solid substrate by providing a pressure differential betweensubstantially parallel surface of a fluid-containing distributionmember.

BACKGROUND

Nucleic acid hybridization is a known method for identifying specificsequences of nucleic acids; hybridization involves base-pairing betweencomplementary nucleic acid strands. When single-stranded nucleic acidsare used as probes to identify specific target sequences of nucleicacids, probes of known sequences are exposed to and incubated in samplesolutions containing sequences to be identified. If a sequencehybridizes to a probe of a known sequence, the sequence is necessarilythe specific target sequence. Various aspects of this method have beenstudied in detail. In essence, all variations allow complementary basesequences to pair and thus form double-stranded stable molecules, and avariety of methods are known in the art to determine whether pairing hasoccurred, such as those described in U.S. Pat. No. 5,622,822 to Ekeze etal. and U.S. Pat. No. 5,256,535 to Ylikoski et al.

Hybridization of surface-bound probes to solution-based targets is aneffective means to analyze a large number of DNA or RNA molecules inparallel. Specific probes of known sequences are attached to the surfaceof a solid substrate in known locations. The probes are usuallyimmobilized on a solid support having a surface area of typically lessthan a few square centimeters. The solid support is typically a glass orfused silica slide which has been treated to facilitate attachment ofprobes. A mobile-phase sample containing labeled targets, e.g., abuffered aqueous solution containing target DNA, is contacted with andallowed to react with the surface. By detecting the labels to determinewhether hybridization has occurred at specific locations, it is possibleto determine the composition of the sample and the sequences of theunknown targets. Alternatively, target biomolecules may be bound to thesurface while labeled probes are contained in the mobile phase. Ineither case, the hybridization reaction typically takes place over atime period that can be many hours, for a typical sample containingtarget material in the concentration range in the picomolar domain.

In the preparation of arrays such as those for use in nucleic acidhybridization, reagents may be applied to predetermined locations on thesurface of a substrate. Generally, a surface is first cleaned orotherwise prepared by exposure to a fluid containing a reagent. Then,array preparation will involve application of biomolecule-containingfluids at discrete locations. For nucleic-acid probe array preparation,the biomolecule-containing fluid may contain the already-formed probesthat can bind with the surface, or a specific nucleotide that will laterconstitute a portion of a probe that is synthesized in situ on thesurface. Then, treatment of a portion of or the entire surface with adifferent fluid may follow. The steps may be repeated a number of timesin situ to prepare the desired array. Once an array of probes is formedon a substrate surface for hybridization with target molecules in asample fluid, hybridization may be carried out by uniformly exposing theentire substrate surface to the sample fluid.

It is apparent, then, that surface coating by a fluid is an importantaspect in array technology, particularly in the field of biomoleculararrays. Important aspects of coating procedures include the amount offluid used and the rate of throughput. In general, coating proceduresshould employ only a small quantity of fluid, for a number of reasons.First, the fluid may contain expensive or rare reagents, and waste ofsuch fluids is undesirable. Second, many ordinary reagents that are usedin array preparation are toxic, and decreasing their use is desirable inorder to lower the risk of human exposure. A high throughput rate alsoimplies that it takes less time to coat each substrate surface, therebyalso lowering the risk of human exposure during the coating procedure.

Another important aspect of coating procedures is uniformity ofcoverage. For biomolecular arrays, it is desirable to uniformly apply afluid onto a substrate surface to ensure that each feature is attachedor formed under similar conditions. In addition, during use of a formedarray containing surface-bound probes, uniform distribution of samplefluid to ensure proper hybridization is necessary. Without uniform fluiddistribution, resultant hybridization data will be compromised.

One method by which a surface may be coated with a small amount of fluidis through the use of a flow cell assembly. Variations on the use of aflow cell are described in U.S. Pat. Nos. 4,596,695 to Cottingham and5,145,784 to Cox et al. The basic flow cell method typically providesthat a cover and substrate are positioned parallel to each other. A gapis thus formed between the cover and the substrate. To control the sizeof the gap, one or more spacers having a selected height are disposedwithin the gap. In addition, the cover, the spacers and the substrateare arranged such that a chamber is provided having an inlet channel andan outlet channel. By creating an appropriate pressure gradient betweenthe inlet and outlet channels, fluid fills the chamber by laminar flow,coating the surface of the substrate within the chamber. By controllingthe volume in the chamber through the proper selection of the spacerheight, the amount of fluid needed to coat the surface can be reduced.

The use of the flow cell method has a number of drawbacks. First,uniform coating requires laminar flow of the fluid. Laminar flow regimegenerally implies that there is an absolute upper limit to thevolumetric rate given the geometry of the chamber. Second, to increasethe flow rate of the fluid, the pressure gradient between the inlet andoutlet channels must be increased. However, pressure surges that aregenerated while increasing the pressure gradient tend to cause the flowcell assembly to leak, either at the cover/support interface or at thesupport/substrate interface. Third, any irregularity in the surfaceprofile of the substrate tends to disrupt laminar flow. As a result, airpockets may be formed and trapped within the flow cell assembly thatwill interrupt contact between the fluid and the substrate. Thus, whilethe use of a flow cell tends to lower the amount of reagent fluid waste,the gain in lowered waste is offset by diminishing throughput.

Spin coating may be employed to quickly and uniformly coat a fluid on asubstrate. Spin coating is usually performed by dispensing the fluid ator near the center of a substrate. The substrate is spun either duringor after the reagent is dispensed such that the fluid spreads radiallyand outwardly to cover the entire substrate. In this method, the volumeneeded to cover a surface depends on fluid property, e.g., viscosity andsurface tension, and the surface energy of the substrate. When a lowenergy surface is provided, a relatively large volume fluid is needed tocover the entire surface. Without sufficient volume, applied fluid tendsto exhibit clustering behavior and does not cover the entire surfaceuniformly. Thus, a relatively large amount of fluid is first applied tothe surface at a low spin speed to cover the entire surface. Then, thesubstrate is spun at a higher speed to remove excess fluid.Consequently, while spin coating may be advantageous in terms of highthroughput, it is a relatively wasteful technique.

Thus, there is a need to provide a method and apparatus to coat asubstrate surface with a small volume of fluid quickly and uniformlywithout relying on spin coating or an ordinary flow cell.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to overcome theabove-mentioned disadvantages of the prior art by providing a method forcoating a substrate surface with a small volume of fluid withoutgenerating excess waste.

It is another object of the invention to provide such a method whereinthe substrate is coated quickly and uniformly.

It is still another object of the invention to provide an apparatus foruse in carrying out the aforementioned method.

It is a further object of the invention to provide such an apparatus foruse in carrying out the aforementioned method with a plurality of fluidsin succession.

Additional objects, advantages and novel features of the invention willbe set forth in part in the description which follows, and in part willbecome apparent to those skilled in the art upon examination of thefollowing, or may be learned by practice of the invention.

In one general aspect, then, the present invention relates to a methodfor applying a fluid onto an application area located on a surface of asolid substrate. The method comprises providing a distribution memberhaving an upper surface and a lower surface, and including a permeableportion having channels of a selected size. The distribution member maybe generally planar and is positioned such that the lower surface of thedistribution member is in generally opposing spacing relation to thesurface of the substrate. The distribution member and the substrate mayalso be substantially uniformly spaced relation. A predetermined volumeof the fluid is dispensed onto the upper surface of the permeableportion of the distribution member such that the fluid penetrates and isretained by the permeable portion of the distribution member. The fluidmay penetrate and be retained by the permeable portion of thedistribution member under the application of a loading pressuredifferential between the upper and lower surfaces. In addition, adistributing pressure differential is applied between the upper andlower surfaces generally without using a movable mechanical meansdesigned to spread fluids such as a squeegee such that at least aportion of the fluid passes through the channels of the permeableportion of the distribution member and onto the application area. Theapplication area may contain any array of biomolecules covalently orotherwise attached thereto.

In another aspect, the invention relates to the above method wherein aperimeter spacer is provided and positioned between and in contact withthe lower surface of the distribution member and the surface of thesolid substrate. Accordingly, the perimeter spacer defines anapplication volume between the lower surface of the distribution memberand the surface. The fluid passes through the channels of the permeableportion of the distribution member and into the application volume.

In still another aspect, the invention relates to the above methodwherein the distribution pressure differential is generated by raisingthe pressure at the second surface of the distribution member. Thedistribution pressure differential may also be generated by lowering thepressure at the lower surface of the distribution member.

In a further aspect, the invention relates to the above method furthercomprising the step of dispensing a second fluid onto the upper surfaceof at least the permeable portion of the distribution member. A pressuredifferential between the upper and lower surfaces is applied such thatthe second fluid passes through the channels in the permeable portion ofthe distribution member and onto the application area, displacing thefluid away from the solid substrate surface. In addition, the method mayfurther comprise the step of flushing a gas through the permeableportion of the distribution member such that the second fluid isdisplaced away from the solid substrate surface. The gas may comprisenitrogen or argon.

In a still further aspect, the invention relates to the above methodwherein the fluid contains water, or an organic solvent such asacetonitrile, an alcohol, or a ketone. Likewise, the fluid may comprisea biomolecule. Examples of biomolecules include oligonucleotides,polynucleotides, oligopeptides and polypeptides. In order to preventfluid waste, it is preferred that the predetermined volume of the fluiddoes not substantially exceed the application volume. More preferably,the predetermined volume of the fluid should not exceed about 150% ofthe application volume. Still more preferably, the predetermined volumeshould not exceed about 110% of the application volume.

In another general aspect, the invention relates to an apparatus forapplying a fluid onto a surface of a solid substrate. The apparatuscomprises a distribution member having an upper surface, a lower surfaceand a permeable portion formed by a plurality of channels extending fromthe upper surface to the lower surface. Such a distribution member maycomprise a perforated flat piece or a mesh. Affixed in sealed contactwith the upper surface about the permeable portion of the distributionmember is an enclosing wall that, together with the distribution member,defines an enclosure having an enclosure volume. The apparatus alsoprovides means for positioning the distribution member in relation tothe solid substrate surface such that the lower surface of thedistribution member is in generally uniformly spaced opposingrelationship to the solid substrate. Once fluid is introduced onto thefluid distribution area within the enclosure, a means for producing apositive pressure differential between the upper surface and the lowersurface of the distribution member can be activated. As a result, theliquid passes through the member and onto the solid substrate surface.

In another aspect, the invention relates to the above apparatus whereina spacer having generally parallel upper and lower surfaces is provided.In such a case, the upper surface of the spacer is affixed to the lowersurface of the distribution member about the permeable portion. Thelower surface is placed in contact with the substrate such that anapplication space having an application volume is substantially enclosedby the spacer, the lower surface of the distribution member, and thesubstrate surface. An opening may be disposed in the spacer such thatthe application space fluidly communicates with open air. In order toprevent fluid waste, it is preferred that the enclosure volume does notsubstantially exceed the application volume. More preferably, theenclosure volume should not exceed about 150% of the application volume.Still more preferably, the enclosure volume should not exceed about 110%of the application volume.

In still another aspect, the invention relates to the above apparatuswherein the means for introducing the fluid comprises a fluid source forsupplying the fluid. A fluid transfer channel is connected to theenclosure and, a fluid valve is disposed between the fluid source andthe fluid transfer channel. Fluid communication is provided from thefluid source to the fluid transfer channel when the fluid valve is open.In addition, the apparatus may include means for introducing a secondfluid. Such means may comprise a second fluid source for supplying thesecond fluid and a second fluid valve disposed between the second fluidsource and the fluid transfer channel, where the second fluid source isin fluid communication with the fluid transfer channel when the secondfluid valve is open. In any case, the fluid may contain a liquid such aswater, acetonitrile, an alcohol, or a ketone for use in facilitatingchemical reactions. Where hybridization reactions are desired, the fluidwill contain a biomolecule such as an oligonucleotide, polynucleotide,oligopeptide, or polypeptide.

In a further aspect, the invention relates to the above apparatuswherein the means for producing a pressure differential may comprisemeans for raising pressure within the chamber. Such pressure raisingmeans may comprise means for introducing a gas into the enclosure from apressured source. The gas may comprise, for example, nitrogen or argon.

In still another general aspect, the invention relates to a reagentapplication station for applying a plurality of reagents onto a surfaceof a solid substrate. The apparatus comprises a distribution memberhaving an upper surface, a lower surface and a permeable portion formedby a plurality of channels extending from the upper surface to the lowersurface. An enclosure is formed by the upper surface of the distributionmember and an enclosing wall affixed about the permeable portion insealed contact with the upper surface of the distribution member. Theapparatus also provides means for positioning the distribution member inrelation to the solid substrate surface such that the lower surface ofthe distribution member is in generally uniformly spaced oppositionrelation to the solid substrate. To control pressure within enclosure, avariable pressure pump is provided having an inlet for each reagent andan outlet in fluid communication with the enclosure. To supply thereagents, a source for each reagent is provided, and a valve is disposedbetween each inlet and source to provide individual control over fluiddispensing. It is preferred that no two valves are open at the sametime.

BRIEF DESCRIPTION OF THE FIGURES

The invention is described in detail below with reference to thefollowing drawings:

FIG. 1 schematically illustrates an apparatus of the present invention.

FIGS. 2A and 2B illustrate alternative embodiments of the distributionmember suitable for use in an apparatus of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Before describing the invention in detail, it must be noted that, asused in this specification and the appended claims, the singular forms“a,” “an,” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to “a fluid” includesmore than one fluid, reference to “a biomolecule” includes a pluralityof biomolecules, reference to “a fluid source” includes a plurality offluid sources and the like.

In describing and claiming the present invention, the followingterminology will be used in accordance with the definitions set outbelow.

The terms “array” is used herein to refer to an ordered pattern offeatures, typically but not necessarily biomolecules, adherent to asubstrate, e.g., a plurality of molecular probes bound to a substratesurface and arranged in a spatially defined and physically addressablemanner. Such probes may be comprised of oligonucleotides, peptides,polypeptides, proteins, antibodies, or other molecules used to detectsample molecules in a sample fluid.

The term “biomolecule” as used herein refers to an organic molecule thatmay be found in a living organism or synthetically produced. Typically,biomolecules are large and may have a complementary counterpart.Examples of biomolecules include but are not limited to nucleotidicmolecules such as oligonucleotides and polynucleotides and peptidicmolecules such as oligopeptides and polypeptides.

The term “feature” refers to an element or a constituent part of matterforming a pattern situated on a surface. As used herein, features can bedeposited, dispensed, printed, placed, positioned or otherwise disposedon a surface.

The term “fluid” as used herein refers to a material that is not purelygaseous which tends to flow to conform to the outline of its container.Unless otherwise stated, the fluids described herein comprise a liquidand may contain solvated gas or fully solvated, partially solvated orsuspended solids.

The term “hybridization” as used herein means binding betweencomplementary or partially complementary molecules, as between the senseand anti-sense strands of double-stranded DNA. Such binding is commonlynon-covalent in nature, and is specific enough that such binding may beused to differentiate between highly complementary molecules and othersless complementary. Examples of highly complementary molecules includecomplementary oligonucleotides, DNA, RNA, and the like, which comprise aregion of nucleotides arranged in the nucleotide sequence that isexactly complementary to a probe; examples of less complementaryoligonucleotides include ones with nucleotide sequences comprising oneor more nucleotides not in the sequence exactly complementary to a probeoligonucleotide.

The term “monomer” as used herein refers to a chemical entity that canbe covalently linked to one or more other such entities to form anoligomer. Examples of “monomers” include nucleotides, amino acids,saccharides, peptides, and the like. In general, the monomers used inconjunction with the present invention have first and second sites(e.g., C-termini and N-termini, or 5′ and 3′ sites) suitable for bindingto other like monomers by means of standard chemical reactions (e.g.,condensation, nucleophilic displacement of a leaving group, or thelike), and a diverse element which distinguishes a particular monomerfrom a different monomer of the same type (e.g., an amino acid surfacechain, a nucleotide base, etc.). The initial substrate-bound monomer isgenerally used as a building-block in a multi-step synthesis procedureto form a complete ligand, such as in the synthesis of oligonucleotides,oligopeptides, and the like.

The terms “nucleoside” and “nucleotide” are intended to include thosemoieties which contain not only the known purine and pyrimidine bases,but also other heterocyclic bases that have been modified. Suchmodifications include methylated purines or pyrimidines, acylatedpurines or pyrimidines, or other heterocycles. In addition, the terms“nucleoside” and “nucleotide” include those moieties that contain notonly conventional ribose and deoxyribose sugars, but other sugars aswell. Modified nucleosides or nucleotides also include modifications onthe sugar moiety, e.g., wherein one or more of the hydroxyl groups arereplaced with halogen atoms or aliphatic groups, or are functionalizedas ethers, amines, or the like. Moreover, the terms “nucleoside” and“nucleotide” include functional analogs (whether synthetic or naturallyoccurring) of such sub units which in the polymer form (as apolynucleotide) can hybridize with naturally occurring polynucleotidesin a sequence specific manner analogous to that of tow naturallyoccurring polynucleotides. For example, these include the sub-units ofPNA and other polynucleotides as described in U.S. Pat. No. 5,948,902and references cited therein (all of which are incorporated herein byreference), regardless of the source.

The term “oligomer” is used herein to indicate a chemical entity thatcontains a plurality of monomers. As used herein, the terms “oligomer”and “polymer” are used interchangeably, as it is generally, although notnecessarily, smaller “polymers” that are prepared using thefunctionalized substrates of the invention, particularly in conjunctionwith combinatorial chemistry techniques. Examples of oligomers andpolymers include polydeoxyribonucleotides, polyribonucleotides, otherpolynucleotides which are—or C-glycosides of a purine or pyrimidinebase, polypeptides, polysaccharides, and other chemical entities thatcontain repeating units of like chemical structure.

The term “probe” as used herein means a biomolecule of known identitythat is typically but not necessarily adherent to a substrate or a basemember of a hybridization package.

The term “reagent” as used herein means a substance used in thepreparation of an array on a surface because of its chemical orbiological activity. Typically, reagents as used herein refer to liquidcompounds or solutions involved the synthesis of biomolecular arrays andinclude, but are not limited to: acetonitrile; buffered solutionscontaining biomolecules; mecaptosilane containing solutions; aqueousiodine solutions; alcohols; acids; bases; oxidizing agents; reducingagents; organic or inorganic fluids for deprotection reactions employedin in situ DNA synthesis; etc.

The term “sample” as used herein relates to a material or mixture ofmaterials, at least partially in fluid form, containing one or morecomponents of interest.

The term “squeegee” as used herein means an implement having an elasticsurface that is used in printing for spreading, pushing, or wiping aliquid material on, across, or off a surface. Unless otherwisespecified, “squeegeeless means” as used herein refer to a means thatexcludes the substantial participation of a blade or other like solidcomponent for spreading, pushing, or wiping of a liquid material bydirect mechanical action.

The term “target” refers to a known or unknown molecule in a sample,which will hybridize to a probe if the target molecule and the molecularprobe contain complementary regions. In general, the target molecule isa “biopolymer,” i.e., an oligomer or polymer such as an oligonucleotide,a peptide, a polypeptide, a protein, an antibody, or the like.

The present invention in general terms is directed to a method forapplying a fluid onto an application area on a surface of a solidsubstrate. Unlike previous methods such as spin coating or flow celltechniques, the present method provides for fast and controlled deliveryof a fluid to coat a surface with little if any waste of the fluid. Themethod employs a generally planar distribution member to hold apredetermined volume of the fluid above the application area. Withoutthe use of a direct mechanical action by a solid component such as asqueegee, a pressure differential is applied between the upper and lowersurfaces of the member to effect flow of the fluid onto the applicationarea of the surface.

The invention is described herein with reference to the figures. Thefigures are not to scale, and in particular, certain dimensions may beexaggerated for clarity of presentation. FIG. 1 schematicallyillustrates an apparatus of the present invention. As shown, theapparatus 10 comprises a distribution member 100 having an upper surface101 and a lower surface 109. The distribution member includes apermeable portion 105 with a plurality of channels 106 therethrough. Thechannels provide communication between the upper and lower surfaces ofthe distribution member. The apparatus also comprises an enclosure 200formed by a tapered cone-shaped wall 210 affixed about the permeableportion and in sealed relation to the upper surface of the distributionmember. As shown, the apparatus 10 further comprises a spacer 300 havinga generally parallel upper surface 301 and lower surface 309. The uppersurface of the spacer is affixed to the lower surface of thedistribution member about the permeable portion. The lower surface ofthe spacer is placed in contact with an upper surface 501 of a solidsubstrate 500. This is done by using means (not shown) for positioningthe distribution member in relation to the solid substrate surface suchthat the lower surface of the distribution member is in generallyuniformly spaced opposing relation to the solid substrate. Such meansare known to one of ordinary skill in the art and include, but are notlimited to, pulleys, levers, gears, and combinations thereof. Inparticular, indexing means typically used in semiconductor waferprocessing may be employed to control positioning with precision andaccuracy. Typically, a chuck of some type (not shown), e.g., vacuum,electrostatic, mechanical, etc., is used to render the solid substrateimmobile while the distribution member is positioned to ensure properalignment with the substrate surface. As a result, the lower surface ofthe distribution member, the spacer, and the substrate substantiallyenclose an application space 400. An optional hole 350 is provided inthe spacer such that an application area 505 located on the surfacewithin the application space fluidly communicates with open air. Theapplication area is the area on the surface of the substrate wheredesired reagents are applied in order to carry out desired reactions.Examples of such reactions include, but are not limited to,functionalization of the surface, in situ chemical synthesis such as ofbiomolecules in an array, and hybridization of surface bound probes witha sample fluid containing target biomolecules. It is envisioned that thefluid may be applied to the application area before, during, or afterthe formation of a particular biomolecular array and that the featuresof the array may be attached to the application area by covalentbonding, electrostatic bonding, polar attraction, Van Der Waal's forcesor other approaches known to one of ordinary skill in the art.

As shown, the enclosure formed by the wall 210 is generally in the formof a cone. For such a conically shaped enclosure, the angle between theenclosing wall and the distribution member, i.e., the base and thesurface of the cone, can be any acute angle between 0° and 90°. It isexpected that an angle of about 10 to about 30° is preferred due tofluid flow, geometric and volume consideration. An angle of about 10 toabout 20° is more preferred, and about 15° should provide optimalresults. As shown, a transfer port 601 is disposed on the enclosingwall. Extending from the transfer port is a fluid transfer channel 600.The apparatus also provides for a source 610 of a fluid. A fluid valveis positioned between the fluid source and the fluid transfer channelsuch that when the fluid valve is open, the fluid source is in fluidcommunication with the fluid transfer channel, which in turn, fluidlycommunicates with the enclosure 200. Preferably, the fluid sourceimposes a loading pressure on the fluid such that when the fluid valveis open, the fluid flows from the source and fills the enclosure,thereby contacting the upper surface of the distribution member. Theloading pressure also effects penetration or retention of the fluid bythe distribution member. Once penetration and retention have beenachieved, the fluid valve is closed.

The apparatus also provides for a source of pressurized gas 630.Disposed between the pressurized gas source and the fluid transferchannel is a gas valve 631 that can regulate the pressure of the gasfrom the gas source. When the gas valve is open such that fluidcommunication is provided between the gas source and the enclosure, thepressurized gas is forced through the fluid transfer channel and intothe enclosure. As a result, pressure within the enclosure is raised withrespect to the pressure at the lower surface of the distribution member,and at least a portion of the fluid passes through the channels of thepermeable portion of the distribution member and onto the applicationarea within the application volume. When the application volume 400 isfilled, the combination of the pressure from the pressurized gas and thephysical contact between the distribution member and the fluid ensuresthat all of the application area is substantially equivalently exposedto the fluid. No squeegee or other like means is employed or necessaryin this process to induce the pressure differential between the upperand lower sides of the distribution member. Once sufficient time haspassed, the gas valve may be opened further such that gas is flushedthrough the permeable portion of the distribution member and at least aportion of the fluid is thereby displaced away from the solid substratesurface.

Particularly in biomolecular array applications, it is a requirementthat the gas used is pure, i.e., does not contain any contaminants orimpurities that could interfere with the function of the fluid.Particulate matter is particularly problematic because such matter maybecome lodged in the distribution member, thereby adversely affectingfluid flow. Suitable gases include, but are not limited to air,nitrogen, argon and other inert gases.

Where it is desired to apply a second fluid after the application of theinitial fluid, a second fluid source 620 is provided as shown in FIG. 1.Disposed between the second fluid source and the fluid transfer channelis a second fluid valve 621. After the initial fluid is displaced awayfrom the solid substrate surface, the second fluid valve is opened torender the second fluid source in fluid communication with the fluidtransfer channel. Preferably, the second fluid source, like the fluidsource, also imposes a loading pressure on the second fluid such thatwhen the second fluid valve is open, the second fluid flows from itssource, fills the enclosure, and contacts the upper surface of thedistribution member. The loading pressure also facilitates penetrationand retention of the second fluid by the distribution member. Oncepenetration and retention have been achieved and the second fluid valveis closed, gas is introduced into the enclosure to cause the secondfluid to flow onto the application area within the application volume.In the alternative, the second fluid may be a wash fluid that is flushedthrough the permeable portion of the distribution member to displace thefluid from the surface of the solid substrate.

It is evident, then, that a method of applying one or more fluids isprovided. One step of the method involves applying a distributionpressure differential between the upper and lower surfaces of thedistribution member for each fluid. Such differential can be applied ina number of ways. For example, pressure at the upper surface of thedistribution member may be raised. In addition, pressure at the lowersurface of the distribution member may be lowered. Furthermore, acombination of pressure raising at the upper surface of the distributionmember and pressure lowering at the lower surface of the distributionmember may be employed. Means for controlling pressure usually involvethe use of a pump as is generally known in the art.

It is also evident that the invention encompasses a reagent applicationstation for applying a plurality of reagent fluids onto a surface of asolid substrate. The station comprises: a distribution member having anupper surface, a lower surface and a permeable portion formed by aplurality of channels extending from the upper surface to the lowersurface; an enclosure formed by an enclosing wall affixed about thepermeable portion in sealed contact with the upper surface of thedistribution member; and means for positioning the distribution memberin relation to the solid substrate surface such that the lower surfaceof the distribution member is in generally uniformly spaced oppositionrelation to the solid substrate. The station also comprises a source foreach reagent; a variable pressure pump having an inlet for each sourceand an outlet in fluid communication with the enclosure; and a valvebetween each inlet and each source. The variable pressure pump should becapable of generating at least two pressures within the enclosure toeffect loading of fluid into the distribution member and dispensing offluid onto the application area of the substrate surface as describedabove. Such a pump may be able to provide a continuous range ofpressures within the enclosure. It is also preferred that no two valvesare open at the same time, to prevent cross-contamination of thesources. Such a condition can be imposed on the station by computerizedmeans known in the art. In addition, computerized means can be used toensure that the reagents are dispensed in a desired sequence.

Although the invention is adaptable for use to distribute a small amountof fluid in a variety of applications and to cover surfaces of any size,the invention is particularly useful in lowering fluid waste in a devicefor forming biomolecular arrays. The geometry, size constraints andother limitations of such a device make it difficult to employ ordinarysilkscreening methods that use a squeegee to coat a surface with afluid. The ordinary biomolecular array device may comprise a substratehaving a contact area in any shape including without limitation, square,rectangular, circular, etc. Substrates having a 3″ by 3″ inch contactarea and substrates having a 6″ by 6″ contact area have been produced.The distance between distribution member and the contact area isordinarily on the order of about 100 microns. However, the distance maybe as low as about 5 microns to as high as about 3000 microns and may becontrolled by the height of the spacer, i.e., the distance between thegenerally parallel upper and lower surface of the spacer. The criticalfactor in determining the distance is the volume of fluid or reagentneeded to effect the desired result. That volume can be readilydetermined. As is apparent from FIG. 1, the application volume isdependent on the contact area and the distance between the distributionmember and the contact area. To lower the amount of fluid waste, it ispreferred that for any application of a particular volume of the fluid,the volume does not substantially exceed the application volume. It isparticularly preferred that the volume of the fluid is no more thanabout 150% of the application volume. Optimally, the volume of the fluidis no more than about 110% of the application volume. In addition, theenclosure volume may correspond to the application volume such that theenclosure volume does not substantially exceed the application volume.

The distribution member is now described. The distribution member may beany of a variety of shapes. However, it is preferred that thedistribution member be generally planar with roughly parallel upper andlower surfaces. The distribution member must include a permeable portionwith a plurality of channels therethrough that provide communicationbetween the upper surface and the lower surface. Thus, the channelsterminate in openings on the upper and lower surfaces of thedistribution member. The cross-sectional area of the channels and theirterminal channels are typically small for a number of reasons. First, afluid dispensed on the upper surface will immediately pass through thepermeable portion of the distribution member if the channels are toolarge. User control of the rate and the manner of fluid distribution isthereby compromised. In addition, it is important to keep in mind theinvention may be adapted to apply a very small amount of fluid to coat asurface. Depending on the surface properties of a particular fluid andsubstrate surface, the fluid may tend to form beads on the substrate.Therefore, the lower surface of the distribution member may be used tomechanically ensure that the distributed fluid uniformly contacts thecontact area of the substrate surface. Holes with large diameters andexcessively long channels may render the distribution member incapableof serving this function. Possible versions of the distribution memberare illustrated in FIGS. 2A and 2B. FIG. 2A illustrates a flat piece 100that is perforated with circular channels 106 extending from oneparallel surface to another. FIG. 2B illustrates a distribution memberhaving a permeable portion comprising a mesh.

When a small amount of fluid is to be applied, surface forces becomeincreasingly important. Thus, the material of the distribution membershould be chosen according to the fluid or fluids to be used. While theinvention may be adapted to apply any number of fluids, typical fluidsthat are used in the formation of biomolecular arrays include, but arenot limited to, those that contain: water; acetonitrile; alcohols suchas methanol, ethanol, propanol, isopropanol, and ethylene glycol; andketones such as acetone and methyl ethyl ketone. In addition, suchfluids may contain biomolecules such as oligonucleotides,polynucleotides, oligopeptides and polypeptides. As a basic requirement,the material from which the distribution member is made must bedimensionally stable to exposure with the components of the fluid orfluids used, if the distribution member is to be used more than once. Inaddition, the material should obviously not impart any undesiredcontaminants into fluid. For example, when acetonitrile is used as asolvent, the distribution member should not be made with a flatperforated piece of polystyrene, since polystyrene is soluble inacetonitrile. In addition, due to the quantity of fluid involved, thematerial should be selected to take advantage of its intrinsic surfaceproperties with respect to the fluid to be dispensed. For example, ifthe fluid contains water, the distribution member may be made from ahydrophobic material such as polytetrafluoroethylene to ensure thatfluid does not wick toward the distribution member from the contact areaof the substrate surface. As will be evident to one of ordinary skill inthe art, coatings may also be applied at specific areas on thedistribution member to selectively control the wetting properties of thespecific areas. As a general rule, ceramic and metallic materials aresuitable for use in distribution members because they are stable withrespect to many fluids and it is possible to make a perforated flatpiece having channels with precision needed to render the inventionoperative. Certain polymers that are resistant to solvents may also be asuitable material.

Variations of the foregoing will be apparent to those knowledgeable inthe art. For example, if a plurality of fluids is dispensed, theapparatus may include more than one fluid transfer channel connected tothe enclosure. In other words, variations known to one of ordinary skillin means of conveying fluids from their sources to the enclosure may beemployed. As another example, a sealing material may be provided anddisposed between two components of the apparatus if sealing contact ismade. As still another example, fastening means may be employed if twocomponents of the invention are affixed to one another.

It is to be understood that while the invention has been described inconjunction with the preferred specific embodiments thereof, that theforegoing description is intended to illustrate and not limit the scopeof the invention. Other aspects, advantages and modifications within thescope of the invention will be apparent to those skilled in the art towhich the invention pertains.

All patents, patent applications, and publications mentioned herein arehereby incorporated by reference in their entireties.

1. An apparatus for applying a fluid onto a surface of a solidsubstrate, comprising: a distribution member having an upper surface, alower surface and a permeable portion formed by a plurality of channelsextending from the upper surface to the lower surface; an enclosurehaving an enclosure volume formed by an enclosing wall affixed about thepermeable portion in sealed contact with the upper surface of thedistribution member; a spacer for positioning the distribution member inrelation to the solid substrate surface such that the lower surface ofthe distribution member is in opposing relation to the solid substratethereby providing an application volume; means for introducing the fluidon to the upper surface of the distribution member within the enclosure;and means for producing a pressure differential between the uppersurface and the lower surface of the distribution member without using asqueegee, whereby the pressure differential causes a portion of thefluid to pass through the member and onto solid substrate surface. 2.The apparatus of claim 1 wherein said spacer comprises, an upper surfaceand a lower surface, the upper spacer surface affixed to the lowersurface of the distribution member about the permeable portion and thelower spacer surface in contact with the substrate surface, such that anapplication space having an application volume is substantially enclosedby the spacer, the lower surface of the distribution member and thesubstrate surface.
 3. The apparatus of claim 2 wherein the upper spacersurface and the lower spacer surfaces are generally parallel surfaces ofthe spacer.
 4. The apparatus of claim 2, further comprising an openingin the spacer such that the application space fluidly communicates withopen air.
 5. The apparatus of claim 2, wherein the enclosure volume isnot substantially greater than the application volume.
 6. The apparatusof claim 1, wherein the enclosure volume is no more than about 150% ofthe application volume.
 7. The apparatus of claim 6, wherein theenclosure volume is no more than about 110% of the application volume.8. The apparatus of claim 1, wherein the distribution member isgenerally planar.
 9. The apparatus of claim 1, wherein the distributionmember is substantially flat and perforated.
 10. The method of claim 1,wherein the distribution member comprises a mesh.
 11. The apparatus ofclaim 1, wherein the means for introducing the fluid comprises a fluidsource for supplying the fluid, a fluid transfer channel connected tothe enclosure and a fluid valve disposed between the fluid source andthe fluid transfer channel, wherein the fluid source is in fluidcommunication with the fluid transfer channel when the fluid valve isopen.
 12. The apparatus of claim 11, further comprising means forintroducing a second fluid, wherein the means for introducing the secondfluid comprises a second fluid source for supplying the second fluid anda second fluid valve disposed between the second fluid source and thefluid transfer channel, wherein the second fluid source is in fluidcommunication with the fluid transfer channel when the second fluidvalve is open.
 13. The apparatus of claim 11, wherein the means forproducing a pressure differential comprises a gas source for supplyingthe gas and a gas valve disposed between the gas source and the fluidtransfer channel, wherein the gas source is in fluid communication withthe fluid transfer channel when the gas fluid valve is open.
 14. Theapparatus of claim 1, wherein the means for producing a pressuredifferential comprises means for raising pressure within the enclosure.15. The apparatus of claim 14, wherein the pressure raising meanscomprises means for introducing a gas into the enclosure from apressured source.
 16. The apparatus of claim 15, wherein the gascomprises nitrogen or argon.
 17. The apparatus of claim 1, wherein thefluid comprises water, acetonitrile, an alcohol, or a ketone.
 18. Theapparatus of claim 1, wherein the fluid contains a biomolecule.
 19. Theapparatus of claim 18, wherein the biomolecule is an oligonucleotide,polynucleotide, oligopeptide, or polypeptide.
 20. A reagent applicationstation for applying a plurality of reagents onto the surface of a solidsubstrate, comprising: a distribution member having an upper surface, alower surface and a permeable portion formed by a plurality of channelsextending from the upper surface to the lower surface; an enclosurehaving an enclosure volume formed by an enclosing wall affixed about thepermeable portion in sealed contact with the upper surface of thedistribution member; a spacer for positioning the distribution member inrelation to the solid substrate surface such that the lower surface ofthe distribution member is in generally uniformly spaced oppositionrelation to the solid substrate thereby providing an application volume;a source for each reagent; a variable pressure pump having an inlet foreach source and an outlet in fluid communication with the enclosure; anda valve between each inlet and each source.
 21. The reagent applicationstation of claim 20, wherein no two valves are open at the same time.